Semiconductor device including cladded base plate

ABSTRACT

A semiconductor device includes a semiconductor chip coupled to a substrate and a base plate coupled to the substrate. The base plate includes a first metal layer clad to a second metal layer. The second metal layer is deformed to provide a pin-fin or fin cooling structure.

BACKGROUND

Power electronic modules are semiconductor packages that are used inpower electronic circuits. Power electronic modules are typically usedin vehicular and industrial applications, such as in inverters andrectifiers. The semiconductor components included within the powerelectronic modules are typically insulated gate bipolar transistor(IGBT) semiconductor chips or metal-oxide-semiconductor field effecttransistor (MOSFET) semiconductor chips. The IGBT and MOSFETsemiconductor chips have varying voltage and current ratings. Thesemiconductor components included within the power electronic modulesmay also include diodes, thyristors, junction gate field-effecttransistors (JFETs), and bipolar transistors. Both passive componentsand control electronics may be included within the power electronicmodules. The semiconductor components are made from Si, SiC, GaN, GaAs,or other suitable substrates. Some power electronic modules includeadditional semiconductor diodes (i.e., free-wheeling diodes) in thesemiconductor package for overvoltage protection.

In general, two different power electronic module designs are used. Onedesign is for higher power applications and the other design is forlower power applications. For higher power applications, a powerelectronic module typically includes several semiconductor chipsintegrated on a single substrate. The substrate typically includes aninsulating ceramic substrate, such as Al₂O₃, AN, Si₃N₄, or othersuitable material, to insulate the power electronic module. At least thetop side of the ceramic substrate is metallized with either pure orplated Cu, Al, or other suitable material to provide electrical andmechanical contacts for the semiconductor chips. The metal layer istypically bonded to the ceramic substrate using a direct copper bonding(DCB) process, a direct aluminum bonding process (DAB) process, or anactive metal brazing (AMB) process.

Typically, soft soldering with Sn—Pb, Sn—Ag, Sn—Ag—Cu, or anothersuitable solder alloy is used for joining a semiconductor chip to ametallized ceramic substrate. Typically, several substrates are combinedonto a planar metal base plate.

In this case, the backside of the ceramic substrate is also metallizedwith either pure or plated Cu, Al, or other suitable material forjoining the substrates to the planar metal base plate. To join thesubstrates to the planar metal base plate, soft soldering with Sn—Pb,Sn—Ag, Sn—Ag—Cu, or another suitable solder alloy is typically used. Theplanar metal base plate may in turn be attached to a cooling elementthrough which a coolant may flow to prevent overheating of the powerelectronic module during operation.

With the increasing desire to use power electronics in harshenvironments (e.g., automotive applications) and the ongoing integrationof semiconductor chips, the externally and internally dissipated heatcontinues to increase. Therefore, there is a growing demand for hightemperature power electronic modules capable of operating with internaland external temperatures up to and exceeding 200° C. In addition, thecurrent density of power electronics continues to increase, which leadsto an increase in the density of power losses. Therefore, liquid coolingof the power electronics via cooling elements to prevent overheating isbecoming increasingly important.

For these and other reasons, there is a need for the present invention.

SUMMARY

One embodiment provides a semiconductor device. The semiconductor deviceincludes a semiconductor chip coupled to a substrate and a base platecoupled to the substrate. The base plate includes a first metal layerclad to a second metal layer. The second metal layer is deformed toprovide a pin-fin or fin cooling structure.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a furtherunderstanding of embodiments and are incorporated in and constitute apart of this specification. The drawings illustrate embodiments andtogether with the description serve to explain principles ofembodiments. Other embodiments and many of the intended advantages ofembodiments will be readily appreciated as they become better understoodby reference to the following detailed description. The elements of thedrawings are not necessarily to scale relative to each other. Likereference numerals designate corresponding similar parts.

FIG. 1 illustrates a cross-sectional view of one embodiment of asemiconductor device.

FIG. 2 illustrates a cross-sectional view of one embodiment of a bimetalribbon (i.e. a bimetal clad strip).

FIG. 3 illustrates a cross-sectional view of one embodiment of atrimetal ribbon (i.e. a trimetal clad strip).

FIG. 4 illustrates a cross-sectional view of one embodiment of a baseplate including a cooling structure.

FIG. 5 illustrates a cross-sectional view of another embodiment of abase plate including a cooling structure.

FIG. 6 illustrates a cross-sectional view of one embodiment of asubstrate assembly.

FIG. 7 illustrates a cross-sectional view of one embodiment substrateassemblies coupled to a base plate.

FIG. 8 illustrates a cross-sectional view of another embodiment ofsubstrate assemblies coupled to a base plate.

FIG. 9 illustrates a cross-sectional view of one embodiment of thesubstrate assemblies, the base plate, terminals, and a frame.

FIG. 10 illustrates a cross-sectional view of one embodiment of thesubstrate assemblies, the base plate, the terminals, the frame, andpotting material.

FIG. 11 illustrates a cross-sectional view of one embodiment of thesubstrate assemblies, the base plate, the terminals, the frame, thepotting material, and a cap.

FIG. 12 illustrates a cross-sectional view of one embodiment of asemiconductor device including a cooling chamber.

FIG. 13 illustrates a cross-sectional view of another embodiment of asemiconductor device including a cooling chamber.

FIG. 14 illustrates a perspective view of another embodiment of asemiconductor device.

FIG. 15 illustrates a perspective view of another embodiment of asemiconductor device.

FIG. 16 is a flow diagram illustrating one embodiment of a method forfabricating a semiconductor device.

DETAILED DESCRIPTION

In the following Detailed Description, reference is made to theaccompanying drawings, which form a part hereof, and in which is shownby way of illustration specific embodiments in which the disclosure maybe practiced. In this regard, directional terminology, such as “top,”“bottom,” “front,” “back,” “leading,” “trailing,” etc., is used withreference to the orientation of the Figure(s) being described. Becausecomponents of embodiments can be positioned in a number of differentorientations, the directional terminology is used for purposes ofillustration and is in no way limiting. It is to be understood thatother embodiments may be utilized and structural or logical changes maybe made without departing from the scope of the present disclosure. Thefollowing detailed description, therefore, is not to be taken in alimiting sense, and the scope of the present disclosure is defined bythe appended claims.

It is to be understood that the features of the various exemplaryembodiments described herein may be combined with each other, unlessspecifically noted otherwise.

As used herein, the term “electrically coupled” is not meant to meanthat the elements must be directly coupled together and interveningelements may be provided between the “electrically coupled” elements.

FIG. 1 illustrates a cross-sectional view of one embodiment of asemiconductor device 100. In one embodiment, semiconductor device 100 isa high temperature (i.e., up to and exceeding 200° C.) high powerelectronic module. Power electronic module 100 includes a coolingchamber 102, a base plate 104, joints 118, substrate assemblies 132 aand 132 b, frame 134, terminals 136, potting 138, and cap 140. Eachsubstrate assembly 132 a and 132 b includes metalized ceramic substrates122 including metal surfaces or layers 120 and 124, joints 126,semiconductor chips 128, and bond wires 130.

Base plate 104 includes a first metal layer 108 and a second metal layer106. First metal layer 108 and second metal layer 106 are made ofdifferent materials. In one embodiment, first metal layer 108 is acopper layer or a copper alloy layer and second metal layer 106 is analuminum layer or an aluminum alloy layer. In other embodiments, firstmetal layer 108 and second metal layer 106 are made of other suitablematerials. In one embodiment, base plate 104 also includes a third metallayer 110 opposite second metal layer 106. Third metal layer 110 andfirst metal layer 108 are made of different materials. In oneembodiment, third metal layer 110 is an aluminum layer or an aluminumalloy layer. In other embodiments, third metal layer 110 is a silverlayer, a silver alloy layer, a palladium layer, a palladium alloy layer,or another suitable material layer. First metal layer 108 is clad tosecond metal layer 106. Third metal layer 110 is clad to first metallayer 108. Second metal layer 106 is structured to provide pin-fins orfins 112 and spaces 114 between pin-fins or fins 112.

Base plate 104 is formed from a bimetal or trimetal ribbon (i.e., acladded strip). Base plate 104 provides a low cost base plate havinggood solderability on one side due to the first metal layer. Inaddition, base plate 104 includes cooling fins or pins on the other sidethat are compatible with a cooling fluid due to the second metal layer.

Cooling chamber 102 includes an inlet 142 and an outlet 144 for passinga cooling fluid through spaces 114 between pin-fins or fins 112 of baseplate 104. Cooling chamber 102 is coupled to base plate 104 via screws116. In other embodiments, screws 116 are not used and cooling chamber102 is glued or laser welded to base plate 104. Each substrate assembly132 a and 132 b is coupled to base plate 104 via joints 118. Joints 118are soft soldered joints, sintered joints, diffusion soldered joints, orother suitable joints.

Ceramic substrates 122 include Al₂O₃, AN, Si₃N₄, or other suitablematerial. In one embodiment, ceramic substrates 122 each have athickness within a range of 0.2 mm to 2.0 mm. Metal layers 120 and 124include Cu, Al, or another suitable material. In one embodiment, metallayers 120 and/or 124 are plated with Ni, Ag, Au, and/or Pd. In oneembodiment, metal layers 120 and 124 each have a thickness within arange of 0.1 mm to 0.6 mm. In one embodiment, metal layers 120 and 124are bonded to ceramic substrate 122 using a direct copper bonding (DCB)process to provide a DCB substrate, a direct aluminum bonding process(DAB) process to provide a DAB substrate, or an active metal brazing(AMB) process to provide an AMB substrate. Joints 126 couple metallayers 124 to semiconductor chips 128. Joints 126 are soft solderedjoints, sintered joints, diffusion soldered joints, or other suitablejoints.

Semiconductor chips 128 are electrically coupled to metal layers 124through bond wires 130. In one embodiment, semiconductor chips 128 arepower semiconductor chips and may include IGBTs, MOSFETs, JFETs, bipolartransistors, thyristors, diodes, and/or other suitable power components.Bond wires 130 include Al, Cu, Al—Mg, Au, or another suitable material.In one embodiment, bond wires 130 are bonded to semiconductor chips 128and metal layers 124 using ultrasonic wire bonding. Metal layers 124and/or semiconductor chips 128 are electrically coupled to terminals136. Terminals 136 extend through frame 134 to provide externalelectrical connections to power electronic module 100 for both power andcontrol connections.

Frame 134 encloses joints 118, substrate assemblies 132 a and 132 b,bond wires 130, and portions of terminals 136. Frame 134 includestechnical plastics or another suitable material. Frame 134 is joined tobase plate 104 via screwing, gluing, clamping, welding, or othersuitable technique. Potting material 138 fills areas within frame 134around joints 118, substrate assemblies 132 a and 132 b, bond wires 130,and portions of terminals 136. Potting material 138 includes siliconegel, a coating of silicone, a coating of polyimide, a coating of epoxy,or another suitable material for providing electrical isolation. Pottingmaterial 138 prevents damage to power electronic module 100 bydielectrical breakdown. Cap 140 is attached to frame 134 to coversubstrate assemblies 132 a and 132 b and potting 138. In one embodiment,cap 104 is a second potting layer, such as epoxy or other suitablecapping material. In another embodiment, cap 104 is a cover assemblythat is attached to frame 134 via snap-in, welding, gluing, or othersuitable technique.

The followings FIGS. 2-13 illustrate a process for fabricating asemiconductor device, such as semiconductor device 100 previouslydescribed and illustrated with reference to FIG. 1.

FIG. 2 illustrates a cross-sectional view of one embodiment of a bimetalribbon (i.e. a bimetal clad strip) 200 a. Bimetal ribbon 200 a includesa first metal layer 108 and a second metal layer 107. First metal layer108 and second metal layer 107 are different materials. In oneembodiment, first metal layer 108 is made of a solderable material andhas a coefficient of thermal expansion (CTE) of less than 18 ppm/K.Second metal layer 107 is selected to be easily machinable (e.g.,shapeable, edgeable, and beadable). In one embodiment, second metallayer 107 is chemically compatible with aluminum in liquid coolingcircuits. In one embodiment, first metal layer 108 is a copper layer ora copper alloy layer and second metal layer 107 is an aluminum layer oran aluminum alloy layer. In other embodiments, first metal layer 108 andsecond metal layer 107 are other suitable metals. In one embodiment, thetotal thickness of bimetal ribbon 200 a is between 5 mm and 6 mm. In oneembodiment, the thickness of first metal layer 108 is equal to thethickness of second metal layer 107. In one embodiment, the thickness offirst metal layer 108 is between 2.5 mm and 3 mm and the thickness ofsecond metal layer 107 is between 2.5 mm and 3 mm. In anotherembodiment, the thickness of first metal layer 108 is between 2.5 mm and10 mm and the thickness of second metal layer 107 is between 2.5 mm and10 mm. In other embodiments, the thickness of first metal layer 108 andthe thickness of second metal layer 107 have other values suitable forforming a base plate.

First metal layer 108 is clad to second metal layer 107. In oneembodiment, first metal layer 108 is clad to second metal layer 107 bybringing the separate layers together in the rolls of a cladding stand.Uniform pressure from the rolls compresses the individual layers to forma bond between the contact surfaces. The bonded layers are thensubjected to recrystallization annealing and rolling to the finishedsize. After rolling to the finished size, the bonded layers aresubjected to another heat treatment to inseparably fuse the layerstogether. In other embodiments, first metal layer 108 is clad to secondmetal layer 107 using another suitable technique.

FIG. 3 illustrates a cross-sectional view of one embodiment of atrimetal ribbon (i.e. a trimetal clad strip) 200 b. Trimetal ribbon 200b includes first metal layer 108 and second metal layer 107, aspreviously described and illustrated with reference to FIG. 2, and athird metal layer 109. Third metal layer 109 and first metal layer 108are different materials. In one embodiment, third metal layer 109 andsecond metal layer 107 are the same material. In one embodiment, thirdmetal layer 109 is aluminum or an aluminum alloy. In other embodiments,third metal layer 109 is silver, a silver alloy, palladium, a palladiumalloy, or another suitable metal. Third metal layer 109 has a thicknessless than the thickness of first metal layer 108 and the thickness ofsecond metal layer 107. In one embodiment, third metal layer 109 has athickness between 1 μm and 0.1 mm. Third metal layer 109 is clad tofirst metal layer 108 opposite second metal layer 107 using a suitabletechnique such as the cladding process previously described withreference to FIG. 2.

While the followings FIGS. 4-13 illustrate the fabrication of asemiconductor device utilizing trimetal ribbon 200 b previouslydescribed and illustrated with reference to FIG. 3, the illustratedprocess is also applicable to bimetal ribbon 200 a previously describedand illustrated with reference to FIG. 2.

FIG. 4 illustrates a cross-sectional view of one embodiment of a baseplate 210 including a cooling structure. Second metal layer 107 of baseplate 200 b previously described and illustrated with reference to FIG.3 is structured to form a cooling structure having pin-fins or fin 112with spaces 114 between the pin-fins or fins 112. Second metal layer 107is deformed via cutting, stamping, or micro deformation technology (MDT)to provided second metal layer 106. MDT mechanically and plasticallydeforms second metal layer 107 to form pin-fins or fins 112 withoutremoving any metal. Second metal layer 107 is deformed such that noportion of the surface of first metal layer 108 facing second metallayer 106 is exposed. By not exposing the surface of first metal layer108, first metal layer 108 is protected from corrosion.

In one embodiment, pin-fins or fins 112 are formed by MDT, pressurecasting, or coining to provide pin-fins or fins 112 having a length asindicated at 113 between 5.5 mm and 6.0 mm. In another embodiment,pin-fins or fins 112 are formed by MDT to provide pin-fins or fins 112having a length as indicated at 113 between 2 mm and 10 mm and spaces114 having a width as indicated at 115 between 1 mm and 10 mm. Inanother embodiment, pin-fins or fins 112 are formed by pressure castingor coining to provide pin-fins or fins 112 having a length as indicatedat 113 between 2 mm and 20 mm and spaces 114 having a width as indicatedat 115 between 1 mm and 20 mm. In other embodiments, pin-fins or fins112 are formed to have other suitable lengths. In one embodiment, holes212 are cut or stamped through base plate 210 for mounting base plate210 to other device structures, such as cooling chamber 102 previouslydescribed and illustrated with reference to FIG. 1.

FIG. 5 illustrates a cross-sectional view of another embodiment of abase plate 220 including a cooling structure. Base plate 220 is similarto base plate 210 previously described and illustrated with reference toFIG. 4 except that base plate 220 excludes holes 212 and third metallayer 109 has been structured to provide third metal layer 110. Portionsof third metal layer 109 are etched, scratched, peeled, or removed usinganother suitable technique to expose portions 222 of first metal layer108 and to provide third metal layer 110. Third metal layer 109 may bestructured to provide third metal layer 110 prior to or after theforming of pin-fins or fins 112. In one embodiment, first metal layer108 includes copper and the structuring of the third metal layerprepares base plate 220 for soldering on the first metal layer. In oneembodiment, third metal layer 110 includes aluminum and provides asolder mask and a solder stop.

FIG. 6 illustrates a cross-sectional view of one embodiment of asubstrate assembly 132 a. Substrate assembly 132 a includes metalizedceramic substrates 122 including metal surfaces or layers 120 and 124,joints 126 a and 126 b, semiconductor chips 128 a and 128 b, and bondwires 130. A first semiconductor chip 128 a is attached to metal layer124 via a first joint 126 a. A second semiconductor chip 128 b isattached to metal layer 124 via a second joint 126 b. Joints 126 a and126 b are soft soldered joints, sintered joints, diffusion solderedjoints, or other suitable joints.

Semiconductor chips 128 a and 128 b are electrically coupled to metallayer 124 through bond wires 130. In one embodiment, semiconductor chips128 a and 128 b are power semiconductor chips and may include IGBTs,MOSFETs, JFETs, bipolar transistors, thyristors, diodes, and/or othersuitable power components. Bond wires 130 include Al, Cu, Al—Mg, Au, oranother suitable material. In one embodiment, bond wires 130 are bondedto semiconductor chips 128 a and 128 b and metal layers 124 usingultrasonic wire bonding. In other embodiments, clips or copper stripsand sintering are used to electrically couple semiconductor chips 128 aand 128 b to metal layer 124. Other substrate assemblies, such assubstrate assembly 132 b previously described and illustrated withreference to FIG. 1 may also be fabricated.

FIG. 7 illustrates a cross-sectional view of one embodiment of substrateassemblies 132 a and 132 b coupled to a base plate 104. Substrateassemblies 132 a and 132 b are coupled to first metal layer 108 viajoints 118. In other embodiments, substrate assemblies 132 a and 132 bare fabricated on base plate 104. In one embodiment, substrateassemblies 132 a and 132 b are soft soldered to first metal layer 108 toprovide solder joints 118. Solder joints 118 include Sn—Pb, Sn—Ag,Sn—Ag—Cu, Sn—Sb, or another suitable solder alloy. In one embodiment,first metal layer 108 includes copper or a copper alloy and third metallayer 110 includes aluminum or an aluminum alloy and provides a soldermask and a solder stop for the soldering process.

In another embodiment, substrate assemblies 132 a and 132 b arediffusion soldered to first metal layer 108 to provide diffusionsoldered joints 118. During the diffusion soldering process, soft solderis completely solidified to provide a pure intermetallic joint (e.g.,Cu₃Sn, Cu₆Sn₅, Ag₃Sn) after the diffusion soldering process. In anotherembodiment, substrate assemblies 132 a and 132 b are sintered to firstmetal layer 108 to provide sintered joints 118. Each sintered joint 118is a sintered metal layer including sintered nanoparticles, such as Agnanoparticles, Au nanoparticles, Cu nanoparticles, or other suitablenanoparticles. Substrate assembly 132 a is electrically coupled tosubstrate assembly 132 b via bond wires 130.

FIG. 8 illustrates a cross-sectional view of another embodiment ofsubstrate assemblies 132 a and 132 b coupled to a base plate includingthird metal layer 109. In this embodiment, third metal layer 109 has notbeen structured to expose first metal layer 108. Substrate assemblies132 a and 132 b are soft soldered, diffusion soldered, or sintered tothird metal layer 109 to provide joints 242. In one embodiment, thirdmetal layer 109 includes silver, a silver alloy, palladium, or apalladium alloy. Third metal layer 109 may provide an interface forsintering or diffusion soldering.

While the following FIGS. 9-13 include joints 118 joining substrateassemblies 132 a and 132 b to first metal layer 108, the embodiments arealso applicable when utilizing joints 242 joining substrate assemblies132 a and 132 b to third metal layer 109.

FIG. 9 illustrates a cross-sectional view of one embodiment of thesubstrate assemblies 132 a and 132 b, the base plate 104, terminals 136,and a frame 134. Frame 134 is attached to base plate 104 via screwing,gluing, clamping, welding, or other suitable method. In one embodiment,frame 134 contacts the upper surface of third metal layer 110 and thesidewalls of first metal layer 108, second metal layer 106, and thirdmetal layer 110. In other embodiments (e.g., FIG. 1), frame 134 onlycontacts the upper surface of third metal layer 110 or first metal layer108 (i.e., if third metal layer 110 is excluded).

Terminals 136 are inserted or formed through frame 134 such that aportion of the terminals 136 extend outside frame 134 for electricalpower and control connections. A portion of terminals 136 extend intoframe 134 for internal electrical connections to substrate assemblies132 a and 132 b. Terminals 136 are electrically coupled to substrateassemblies 132 a and 132 b via bond wires 130. In other embodiments,terminals 136 are directly electrically coupled to substrate assemblies132 a and 132 b via welding or another suitable technique.

FIG. 10 illustrates a cross-sectional view of one embodiment of thesubstrate assemblies 132 a and 132 b, the base plate 104, the terminals136, the frame 134, and potting material 138. In one embodiment, asilicone gel is applied over substrate assemblies 132 a and 132 b withinframe 134 to provide potting 138. In other embodiments, substrateassemblies 132 a and 132 b are coated with silicone, polymide, epoxy, orother suitable material to provide electrical isolation.

FIG. 11 illustrates a cross-sectional view of one embodiment of thesubstrate assemblies 132 a and 132 b, the base plate 104, the terminals136, the frame 134, the potting material 138, and a cap 140. In oneembodiment, a second potting material, such as epoxy, is applied overpotting 138 to provide cap 140. In another embodiment, a cover assemblyis attached to frame 134 via snap-in, welding, gluing, or anothersuitable method to provide cap 140.

FIG. 12 illustrates a cross-sectional view of one embodiment of asemiconductor device 100 including a cooling chamber 102. Coolingchamber 102 is attached to base plate 104 via screws 116. In otherembodiments, cooling chamber 102 is attached to base plate 104 viagluing, welding, or another suitable method. In one embodiment, coolingchamber 102 is made from aluminum or an aluminum alloy. In otherembodiments, cooling chamber 102 is made from another suitable materialcompatible with the cooling fluid. Cooling chamber 102 includes an inletand an outlet. In one embodiment, cooling chamber 102 guides coolingfluid to hot areas in an optimum way to compensate for minor differencesin junction temperatures of paralleled or different semiconductor chips.

FIG. 13 illustrates a cross-sectional view of another embodiment of asemiconductor device 300 including a cooling chamber 302. In thisembodiment, cooling chamber 302 is fabricated by laser welding or gluinga thin metal layer to second metal layer 106 of base plate 104. The thinmetal layer is glued or laser welded to second metal layer 106 at aplurality of points as indicated for example at 304. The location ofconnection points 304 may be selected to adjust the pressure and/or flowof the cooling fluid through the cooling chamber. In one embodiment, thethin metal layer is aluminum or an aluminum alloy. In other embodiments,the thin metal layer is another suitable material that is compatiblewith the cooling fluid. Semiconductor device 300 also includes holes 212that extend through base plate 104 and cooling chamber 302. Holes 212may be used to attach semiconductor device 300 to another structure.

FIG. 14 illustrates a perspective view of another embodiment of asemiconductor device 320. In one embodiment, semiconductor device 320 isa high power electronic module. Power electronic module 320 includes abase plate 322, a frame 324, power semiconductor chips 326, powerterminals 328, 330, and 332, and control terminals 334. In oneembodiment, power terminals 228 are negative terminals, power terminals330 are positive terminals, and power terminals 332 are phase outputterminals.

Terminals 238, 330, 332, and 334 are electrically coupled to powersemiconductor chips 326 via bond wires 336. Terminals 328, 330, 332, and334 are pressfit-pins each having the same dimensions such that a singleterminal type is used for all terminals of power electronic module 320.In addition, terminals 328, 330, 332, and 334 extend through frame 324around the periphery of power electronic module 320. In one embodiment,base plate 322 is similar to base plate 104 previously described andillustrated with reference to FIG. 1.

FIG. 15 illustrates a perspective view of another embodiment of asemiconductor device 360. Semiconductor device 360 is similar tosemiconductor device 320 previously described and illustrated withreference to FIG. 14 except that semiconductor device 360 includes a cap362 and base plate 322 has been replaced with base plate 364. Cap 362 isa snap-in cap. Base plate 364 includes pin-fins 366. In one embodiment,base plate 364 is similar to base plate 104 previously described andillustrated with reference to FIG. 1.

FIG. 16 is a flow diagram illustrating one embodiment of a method 400for fabricating a semiconductor device, such as semiconductor device 100previously described and illustrated with reference to FIGS. 1 and 12 orsemiconductor device 300 previously described and illustrated withreference to FIG. 13. At 402, a bimetal or trimetal ribbon (i.e., acladded strip) is formed (e.g., as previously described and illustratedwith reference to FIGS. 2 and 3). At 404, the bottom layer of thecladded strip is deformed to form a base plate with a pin-fin or fincooling structure (e.g., as previously described and illustrated withreference to FIG. 4). At 406, substrates and semiconductor chips (e.g.,substrate assemblies or separate components) are attached to the baseplate (e.g., as previously described and illustrated with reference toFIG. 7). At 408, the frame is assembled, potting is added, and thepackage is closed (e.g., as previously described and illustrated withreference to FIGS. 9-11). At 410, a cooling chamber is attached to thebase plate (e.g., as previously described and illustrated with referenceto FIGS. 12 and 13).

Embodiments provide a semiconductor device including a cladded bimetalor trimetal base plate including a cooling structure. The cladded baseplate provides a low cost solution for providing a base plate includinga first metal layer suitable for joining to substrate assemblies and asecond metal layer suitable for forming a cooling structure that iscompatible with cooling fluids. In addition, the bond between the cladlayers is significantly stronger than other technologies such as coldgas spray or bimetallic extrusion.

Although specific embodiments have been illustrated and describedherein, it will be appreciated by those of ordinary skill in the artthat a variety of alternate and/or equivalent implementations may besubstituted for the specific embodiments shown and described withoutdeparting from the scope of the present disclosure. This application isintended to cover any adaptations or variations of the specificembodiments discussed herein. Therefore, it is intended that thisdisclosure be limited only by the claims and the equivalents thereof.

What is claimed is:
 1. A semiconductor device comprising: asemiconductor chip coupled to a substrate; and a base plate coupled tothe substrate such that the substrate is between the semiconductor chipand the base plate, the base plate comprising a first metal layerdirectly clad to a second metal layer, the second metal layer deformedto provide a planar portion and a pin-fin or fin cooling structureextending from the planar portion, wherein the first metal layercomprises a first material and the second metal layer comprises a secondmaterial different from the first material, and wherein the substratecomprises a ceramic layer, a third metal layer directly coupled to afirst side of the ceramic layer, and a fourth metal layer directlycoupled to a second side of the ceramic layer opposite the first side.2. The semiconductor device of claim 1, wherein the first metal layercomprises copper and the second metal layer comprises aluminum.
 3. Thesemiconductor device of claim 1, wherein the first metal layer has athickness between 2.5 mm and 10 mm and the second metal layer has athickness between 2.5 mm and 10 mm.
 4. The semiconductor device of claim1, further comprising: a fifth metal layer clad to the first metal layeropposite the second metal layer.
 5. The semiconductor device of claim 4,wherein the fifth metal layer has a thickness between 1 μm and 0.1 mm.6. The semiconductor device of claim 4, wherein the fifth metal layercomprises one of silver and palladium.
 7. The semiconductor device ofclaim 6, further comprising: one of a diffusion soldered joint and asintered joint between the substrate and the fifth metal layer.
 8. Thesemiconductor device of claim 4, wherein the fifth metal layer comprisesaluminum.
 9. The semiconductor device of claim 8, wherein the fifthmetal layer is structured to provide a solder stop layer, thesemiconductor device further comprising a soldered joint between thesubstrate and the first metal layer.
 10. A semiconductor devicecomprising: a first metallized ceramic substrate comprising a ceramiclayer, a first metal layer directly coupled to a first side of theceramic layer, and a second metal layer directly coupled to a secondside of the ceramic layer opposite the first side of the ceramic layer;a first semiconductor chip coupled to a first side of the firstmetallized ceramic substrate; and a base plate coupled to a second sideof the first metallized ceramic substrate, the second side of the firstmetallized ceramic substrate opposite the first side of the firstmetallized ceramic substrate, the base plate comprising a first layercomprising copper clad to a second layer comprising aluminum, the secondlayer deformed to provide a planar portion and a pin-fin or fin coolingstructure.
 11. The semiconductor device of claim 10, further comprising:a second semiconductor chip coupled to the first side of the firstmetallized ceramic substrate.
 12. The semiconductor device of claim 10,further comprising: a second metallized ceramic substrate; and a secondsemiconductor chip coupled to a first side of the second metallizedceramic substrate, wherein the base plate is coupled to a second side ofthe second metallized ceramic substrate, the second side opposite thefirst side.
 13. The semiconductor device of claim 10, furthercomprising: a cooling chamber including an inlet and an outlet, thecooling chamber surrounding the cooling structure; a frame attached tothe base plate; potting surrounding the semiconductor chip and thesubstrate; and a cap over the potting.
 14. The semiconductor device ofclaim 10, further comprising: a power terminal electrically coupled tothe first semiconductor chip; and a control terminal electricallycoupled to the first semiconductor chip, wherein the power terminal andthe control terminal have the same dimensions.